Cushioning article with tensile component and method of manufacturing a cushioning article

ABSTRACT

A cushioning article comprises a first and a second polymeric sheet bonded to one another and enclosing an interior cavity. The polymeric sheets retain a gas in the interior cavity. A tensile component disposed in the interior cavity includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the interior cavity and connecting the first tensile layer to the second tensile layer. An inwardly-protruding bond joins the first polymeric sheet to the first tensile layer, protrudes inward from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymeric sheet is displaced from the first tensile layer adjacent to the inwardly-protruding bond by the gas. A method of manufacturing a cushioning article is disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. Nonprovisional application Ser.No. 15/982,749 filed on May 17, 2018, which claims the benefit ofpriority to U.S. Provisional Application No. 62/508,044 filed on May 18,2017, and both of which are hereby incorporated by reference in theirentirety.

TECHNICAL FIELD

The present teachings generally include a cushioning article having atensile component, and a method of manufacturing the cushioning articlewith an inwardly-protruding bond.

BACKGROUND

A cushioning article, such as a sole component of an article offootwear, is typically configured to provide cushioning, motion control,and/or resilience. Some cushioning articles utilize a sealed interiorcavity filled with a gas that resiliently reacts a compressive load. Atensile component may be disposed in the interior cavity, and may limitthe outward expansion of the cushioning article.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration in plan view of a cushioning articlein accordance with the present teachings.

FIG. 2 is a schematic illustration in bottom view of the cushioningarticle of FIG. 1 .

FIG. 3 is a schematic illustration in cross-sectional view of thecushioning article of FIG. 1 , taken at lines 3-3 in FIG. 1 .

FIG. 4 is a schematic illustration in close-up cross-sectional view of aportion of the cushioning article of FIG. 3 .

FIG. 5 is a schematic illustration in close-up cross-sectional view ofthe cushioning article of FIG. 4 under loading in a first stage ofcompression.

FIG. 6 is a schematic illustration in close-up cross-sectional view ofthe cushioning article of FIG. 4 under loading in a second stage ofcompression.

FIG. 7 is a schematic illustration in close-up cross-sectional view ofthe cushioning article of FIG. 4 under loading in a third stage ofcompression.

FIG. 8 is a schematic illustration in cross-sectional view of thecushioning article of FIG. 1 , taken at lines 8-8 in FIG. 1 .

FIG. 9 is a schematic illustration in medial side view of an article offootwear with a sole structure that includes the cushioning article ofFIG. 1 , indicated in hidden lines.

FIG. 10 is a schematic illustration in plan view of a cushioning articlein accordance with an alternative aspect of the present teachings.

FIG. 11 is a schematic illustration in bottom view of the cushioningarticle of FIG. 10 .

FIG. 12 is a schematic illustration in fragmentary cross-sectional viewof the cushioning article of FIG. 10 , taken at lines 12-12 in FIG. 10 .

FIG. 13 is a schematic illustration in medial side view of thecushioning article of FIG. 1 .

FIG. 14 is a schematic illustration in medial side view of thecushioning article of FIG. 10 .

FIG. 15 is a schematic illustration in exploded cross-sectional view ofcomponents of the cushioning article of FIG. 1 and a mold used inmanufacturing the cushioning article.

FIG. 16 is a schematic illustration of the components of the cushioningarticle of FIG. 1 in the mold of FIG. 16 , with the mold in a closedposition.

FIG. 17 is a schematic perspective illustration of a mold portion formanufacturing cushioning components.

FIG. 18 is a schematic perspective illustration of the mold portion ofFIG. 17 with a first mold insert secured to the mold portion.

FIG. 19 is a schematic perspective illustration of a second mold insertfor use with the mold portion of FIG. 17 .

FIG. 20 is a flow chart of a method of manufacturing a cushioningarticle.

FIG. 21 is a schematic illustration in plan view of a cushioning articlein accordance with an alternative aspect of the present teachings.

FIG. 22 is a schematic illustration in bottom view of the cushioningarticle of FIG. 21 .

FIG. 23 is a schematic illustration in cross-sectional view of thecushioning article of FIG. 21 , taken at lines 23-23 in FIG. 21 .

FIG. 24 is a schematic illustration in medial side view of thecushioning article of FIG. 21 .

DESCRIPTION

A cushioning article comprises a bladder enclosing an interior cavityand retaining a gas in the interior cavity. A tensile component isdisposed in the interior cavity and includes tensile layers and aplurality of tethers connecting the tensile layers. The tensile layersare connected to an inner surface of the bladder such that the tethersspan across the interior cavity. The bladder has a plurality of bondsarranged in closed shapes surrounding domed portions of the bladder. Theplurality of bonds bond the inner surface of the bladder to the tensilecomponent. The domed portions of the bladder are unbonded to the tensilecomponent and are therefore displaced from the tensile component by thegas.

In one or more embodiments, the bladder comprises a first polymericsheet and a second polymeric sheet bonded to one another at a peripheralflange and enclosing the interior cavity. The tensile layers include afirst tensile layer connected to the first polymeric sheet and a secondtensile layer connected to the second polymeric sheet. At least one ofthe first polymeric sheet and the second polymeric sheet includes thedomed portions.

The plurality of bonds may protrude inward into the interior cavity andpartially traverse the plurality of tethers such that the bladder isnarrowed at the plurality of bonds. When an inflation pressure of thegas in the interior cavity is sufficient to tension the plurality oftethers, the plurality of bonds defines grooves at an outer surface ofthe bladder such that the cushioning article is articulated along thegrooves.

The plurality of bonds may be a first plurality of bonds in a firstregion of the bladder, and the bladder may have a second plurality ofbonds arranged in closed shapes in a second region of the bladder.Portions of the bladder surrounded by the closed shapes in the secondregion may be bonded to the tensile component.

The cushioning article may be for a variety of applications, such as butnot limited to a sole component of an article of footwear. In such anembodiment, the first region may be on a distal side of the bladder(i.e., a ground contact side), and the second region may be on aproximal side of the bladder (i.e., a foot-facing side). In otherembodiments, the first region and the second region are both on a distalside of the bladder or are both on a proximal side of the bladder. Instill other embodiments, the plurality of bonds are a first plurality ofbonds in a first region of the bladder, and the bladder has a secondplurality of bonds arranged in closed shapes in a second region of thebladder. Portions of the bladder surrounded by the closed shapes in thesecond region are unbonded to the tensile component and form domedportions that are displaced from the tensile component by the gas. Forexample, both the proximal side and the distal side of the cushioningarticle may have the domed portions.

A cushioning article comprises a first polymeric sheet and a secondpolymeric sheet bonded to one another and enclosing an interior cavity.The first polymeric sheet and the second polymeric sheet retain a gas inthe interior cavity. A tensile component is disposed in the interiorcavity. The tensile component includes a first tensile layer, a secondtensile layer, and a plurality of tethers spanning the interior cavityfrom the first tensile layer to the second tensile layer and connectingthe first tensile layer to the second tensile layer. Aninwardly-protruding bond joins the first polymeric sheet to the firsttensile layer, protrudes inward from the first polymeric sheet towardthe second polymeric sheet, and partially traverses the plurality oftethers. The first polymeric sheet is displaced from the first tensilelayer adjacent to the inwardly-protruding bond by the gas. Theinwardly-protruding bond is spaced apart from the second polymeric sheetsuch that the interior cavity is narrowed at the inwardly-protrudingbond and the gas in the interior cavity fluidly communicates across theinwardly-protruding bond. Accordingly, the consistency andresponsiveness of tethers in returning the interior cavity to itsoriginal shape following a dynamic compressive load is combined withstaged cushioning, and the flexibility of an articulated cushioningcomponent, with articulation occurring in alignment with the tetherstraversed by the inwardly-protruding bond.

In one or more embodiments, the cushioning article is a sole componentfor an article of footwear, and the inwardly-protruding bond establishesa flexion axis of the sole component. Accordingly, the cushioningcomponent may be articulated at the inwardly-protruding bond, and theflexion axes may be aligned with desired flexion regions of a foot, forexample, such as the metatarsal-phalangeal joints.

In one or more embodiments, a portion of the interior cavity at a firstside of the inwardly-protruding bond is in fluid communication with aportion of the interior cavity at a second side of theinwardly-protruding bond, with the second side opposite of the firstside. The gas in the interior cavity can thus be displaced across theinwardly-protruding bond, such as during a foot strike or foot roll ofan article of footwear when the cushioning article is included in a solestructure.

In one or more embodiments, an inflation pressure of the gas in theinterior cavity is sufficient to tension the plurality of tethers at theinwardly-protruding bond, and the inwardly-protruding bond defines agroove at an outer surface of the first polymeric sheet such that thecushioning article is divided into a first article portion on one sideof the groove and a second article portion on the other side of thegroove, and the first article portion is articulated relative to thesecond article portion along the groove.

In one or more embodiments, the first tensile layer is spaced apart fromthe second tensile layer by a first distance at a location adjacent tothe inwardly-protruding bond, and the inwardly-protruding bond is spacedapart from the second tensile layer by a second distance. The seconddistance is between 50 percent and 80 percent of the first distance.Narrowing of the interior cavity by this ratio may provide an optimalrange of articulation that contributes to flexibility of the cushioningarticle.

Because the inwardly-protruding bond at least partially traverses theplurality of tethers, in one or more embodiments, the plurality oftethers includes tethers aligned with the inwardly-protruding bond andtethers displaced from the inwardly-protruding bond. The tethers alignedwith the inwardly-protruding bond are shorter, thicker, or both shorterand thicker than the tethers displaced from the inwardly-protrudingbond. The tethers are originally all of the same length and width priorto manufacturing the cushioning article and establishing theinwardly-protruding bond. The deformation of the tethers that occursduring manufacturing at the inwardly-protruding bond contributes to thearticulation and flexibility of the cushioning article.

In one or more embodiments, the inwardly-protruding bond defines aclosed shape surrounding a portion of the first polymeric sheetdisplaced from the first tensile layer such that the portion of thefirst polymeric sheet has a domed surface extending away from the firsttensile layer.

In some embodiments, the second polymeric sheet is recessed inwardtoward the inwardly-protruding bond of the first polymeric sheet whenthe interior cavity is inflated. In other embodiments, the secondpolymeric sheet also has inwardly-protruding bonds.

In some embodiments, the inwardly-protruding bond may be a firstinwardly-protruding bond, the portion of the first polymeric sheetsurrounded by the closed shape is a first portion of the first polymericsheet in a first region of the first polymeric sheet, an inner surfaceof a second portion of the first polymeric sheet in a second region ofthe first polymeric sheet spaced apart from the first region is bondedto an outer surface of the first tensile layer; and the cushioningarticle may further comprise a second inwardly-protruding bond thatjoins the first polymeric sheet to the first tensile layer and protrudesfrom the first polymeric sheet toward the second polymeric sheet in thesecond region and partially traverses the tensile component. The secondinwardly-protruding bond may be spaced apart from the second polymericsheet such that the interior cavity is narrowed at the secondinwardly-protruding bond and the gas in the interior cavity fluidlycommunicates across the second inwardly-protruding bond.

A method of manufacturing a cushioning article comprises disposinganti-weld material on at least one of an inner surface of a firstpolymeric sheet and an outer surface of a first tensile layer of atensile component. The tensile component includes the first tensilelayer, a second tensile layer, and a plurality of tethers connecting thefirst tensile layer to the second tensile layer. The method furthercomprises conforming the first polymeric sheet and a second polymericsheet to components of a mold. Conforming the first polymeric sheet inthis manner depresses the first polymeric sheet toward the secondpolymeric sheet at protrusions of the mold arranged in closed shapes andwith the protrusion directly outward of the plurality of tethers. Themethod further comprises thermally bonding the first tensile layer tothe first polymeric sheet and the second tensile layer to the secondpolymeric sheet opposite the first tensile layer. Thermally bonding thetensile layers to the polymeric sheets in this manner produces aplurality of bonds at the protrusion that joins the first polymericsheet to the first tensile layer and partially traverses the pluralityof tethers. The plurality of bonds protrude toward the second polymericsheet and are spaced apart from the second tensile layer and the secondpolymeric sheet. The first polymeric sheet is separated from the firsttensile layer adjacent to the inwardly-protruding bonds due to theanti-weld material such that portions of the first polymeric sheetsurrounded by the plurality of bonds forming the closed shapes aredisplaceable from the first tensile layer. For example, when inflated, aportion of the first polymeric surrounded by bonds forming a closedshape forms a domed surface.

In one or more embodiments, the method further comprises bonding thefirst polymeric sheet to the second polymeric sheet at a peripheral bondsuch that the first polymeric sheet and the second polymeric sheet atleast partially enclose an interior cavity containing the tensilecomponent. The plurality of tethers span across the interior cavity fromthe first tensile layer to the second tensile layer. The plurality ofbonds protrudes inward such that the interior cavity is narrowed at theinwardly-protruding bond.

In one or more embodiments, the method further comprises inflating andsealing the interior cavity. Inflating the interior cavity in thismanner lifts the portions of the first polymeric sheet surrounded by theclosed shapes away from the tensile component to form the domedportions, and tensions the plurality of tethers at the plurality ofbonds to creates a plurality of grooves in an outer surface of the firstpolymeric sheet at the plurality of bonds, thereby articulating thecushioning article. For example, the cushioning article may be a solecomponent for an article of footwear, and the groove may establish aflexion axis of the sole component.

In one or more embodiments, the components of the mold include a firstmold portion and a second mold portion. At least one of the first moldportion and the second mold portion is translatable relative to theother of the first mold portion and the second mold portion between anopen position and a closed position. Bonding the first polymeric sheetand the second polymeric sheet at the peripheral bond includescompressing the first polymeric sheet and the second polymeric sheetbetween the first mold portion and the second mold portion in the closedposition.

In one or more embodiments, the mold component having the plurality ofprotrusions is one of the first mold portion and the second moldportion. Alternatively, in other embodiments, the mold component havingthe plurality of protrusions is a mold insert. This enables the bondpattern of the cushioning articles manufactured according to the methodto be easily changed by changing the mold insert to a different moldinsert that has a different pattern of protrusions. For example, themethod may further comprise, prior to conforming the first polymericsheet and the second polymeric sheets to components of the mold,securing a mold insert to a mold portion of the mold, and wherein themold component having the plurality of protrusions is the mold insert.In some embodiments, the mold insert is a first mold insert, the moldportion is a first mold portion, the plurality of bonds is a firstplurality of bonds, and the method further comprises securing a secondmold insert to a second mold portion of the mold, wherein the secondmold insert has a second plurality of protrusions directly opposite thefirst plurality of protrusions and outward of the plurality of tethers.In such an embodiment, conforming the first and second polymeric sheetsand thermally bonding the first tensile layer to the first polymericsheet and the second tensile layer to the second polymeric sheetproduces a second plurality of bonds at the second plurality ofprotrusions partially traversing the tensile component directly oppositethe first plurality of bonds. The second plurality of bonds protrudestoward the first plurality of bonds and the first polymeric sheet, andis spaced apart from the first plurality of bonds, the first tensilelayer, and the first polymeric sheet.

In one or more embodiments, the cushioning article is a first cushioningarticle, and the method further comprises manufacturing a secondcushioning article by removing the mold insert from the mold portion,and securing a second mold insert having a second plurality ofprotrusions to the mold portion. The second plurality of protrusions isshaped, dimensioned or positioned differently than the first pluralityof protrusions. The method further comprises conforming a subsequentfirst polymeric sheet and a subsequent second polymeric sheet to thesecond mold insert and to another one of the components of the mold,respectively, with a subsequent tensile component between the subsequentfirst polymeric sheet and the subsequent second polymeric sheet.Conforming the subsequent first and second polymeric sheets in thismanner depresses the subsequent first polymeric sheet toward thesubsequent second polymeric sheet at the second plurality ofprotrusions, with the second plurality of protrusions directly outwardof the subsequent tensile component, thereby producing a secondplurality of bonds at the second plurality of protrusions partiallytraversing the subsequent tensile component. The mold thus provides thesecond cushioning article with a different bond pattern than the firstcushioning article due to the second mold insert.

In one or more embodiments, conforming the first polymeric sheet and thesecond polymeric sheet to components of the mold is by vacuum,compression, or both. Additionally, in one or more embodiments, thermalbonding of the first tensile layer to the first polymeric sheet and thesecond tensile layer to the second polymeric sheet includes at least oneof heating the first polymeric sheet and the second polymeric sheet,heating the mold components, or radio frequency welding.

The above features and advantages and other features and advantages ofthe present teachings are readily apparent from the following detaileddescription of the modes for carrying out the present teachings whentaken in connection with the accompanying drawings.

Referring to the drawings, wherein like reference numbers refer to likecomponents throughout the views, FIG. 1 shows a cushioning article 10that may be manufactured according to a method 210 of FIG. 20 and hasfeatures that provide a desirable combination of cushioning andflexibility. The cushioning article 10 is shown and described as acushioning article used in a sole structure 12 of an article of footwear14, shown in FIG. 9 . The cushioning article 10 is a full lengthcushioning article for a sole structure 12, as it has a forefoot region17A, a midfoot region 17B, and a heel region 17C. The forefoot region17A may be generally associated with the toes and joints connecting themetatarsals with the phalanges. The midfoot region 17B may be generallyassociated with the arch of a foot. The heel region 17C may be generallyassociated with the heel of a foot, including the calcaneus bone. Thecushioning article 10 has a lateral side 19 and a medial side 21. Inparticular, the lateral side 19 and the medial side 21 may be opposingsides of the cushioning article 10, and may extend along the forefootregion 17A, the midfoot region 17B, and the heel region 17C. In theembodiment of the cushioning article 10 shown in FIGS. 1 and 2 , thefirst polymeric sheet 16 establishes the proximal side of the bladder 23(i.e., the side closest to the foot when assembled in an article offootwear). The second polymeric sheet 18 establishes the distal side ofthe bladder 23 (i.e., the ground-facing side of the bladder).

In FIG. 9 , the cushioning article 10 is shown at least partiallyencased in a foam sole layer 11, and together the cushioning article 10and sole layer 11 serve as a midsole of the sole structure 12. Anoutsole, an insole, and other sole components may also be included inthe sole structure 12. The cushioning article 10 is thus a solecomponent. However, the cushioning article 10 or other cushioningarticles manufactured according to the method 210 may be used in otherarticles, such as athletic apparel, sports equipment, furniture, andfloor mats. For example, the cushioning article may be for a backpackstrap, a helmet cushion, a shin guard, a baseball glove, a seat cushion,or a floor mat.

Referring to FIGS. 1-3 , the cushioning article 10 includes a bladder 23having a first polymeric sheet 16 and a second polymeric sheet 18 bondedto one another at a peripheral bond 20 to enclose an interior cavity 22.When the sheets 16, 18 are bonded together at the peripheral bond 20 andany inflation port 82 is sealed, the first polymeric sheet 16 and thesecond polymeric sheet 18 retain a fluid in the interior cavity 22. Asused herein, a “fluid” filling the interior cavity 22 may be a gas, suchas air, nitrogen, another gas, or a combination thereof.

The first and second polymeric sheets 16, 18 can be a variety ofpolymeric materials that can resiliently retain a fluid such asnitrogen, air, or another gas. Examples of polymeric materials for thefirst and second polymeric sheets 16, 18 include thermoplastic urethane,polyurethane, polyester, polyester polyurethane, and polyetherpolyurethane. Moreover, the first and second polymeric sheets 16, 18 caneach be formed of layers of different materials including polymericmaterials. In one embodiment, each of the first and second polymericsheets 16, 18 is formed from thin films having one or more thermoplasticpolyurethane layers with one or more barrier layers of a copolymer ofethylene and vinyl alcohol (EVOH) that is impermeable to the pressurizedfluid contained therein such as a flexible microlayer membrane thatincludes alternating layers of a gas barrier material and an elastomericmaterial, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonket al. which are incorporated by reference in their entireties.Alternatively, the layers may include ethylene-vinyl alcohol copolymer,thermoplastic polyurethane, and a regrind material of the ethylene-vinylalcohol copolymer and thermoplastic polyurethane. Additional suitablematerials for the first and second polymeric sheets 16, 18 are disclosedin U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy which are incorporatedby reference in their entireties. Further suitable materials for thefirst and second polymeric sheets 16, 18 include thermoplastic filmscontaining a crystalline material, as disclosed in U.S. Pat. Nos.4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyesterpolyol, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and6,321,465 to Bonk et al. which are incorporated by reference in theirentireties. In selecting materials for the cushioning article 10,engineering properties such as tensile strength, stretch properties,fatigue characteristics, dynamic modulus, and loss tangent can beconsidered. For example, the thicknesses of the first and secondpolymeric sheets 16, 18 used to form the cushioning article 10 can beselected to provide these characteristics.

As best shown in FIG. 3 , the cushioning article 10 includes a tensilecomponent 30 disposed in the interior cavity 22. The tensile component30 includes a first tensile layer 32, a second tensile layer 34, and aplurality of tethers 36 spanning the interior cavity 22 from the firsttensile layer 32 to the second tensile layer 34. The tethers 36 connectthe first tensile layer 32 to the second tensile layer 34. Only some ofthe tethers 36 are indicated with reference numbers in FIG. 3 . Thetethers 36 may also be referred to as fabric tensile members or threads,and may be in the form of drop threads that connect the first tensilelayer 32 and the second tensile layer 34. The tensile component 30 maybe formed as a unitary, one-piece textile element having a spacer-knittextile. It should be appreciated that the first tensile layer 32 andthe second tensile layer 34 are permeable by the gas in the interiorcavity. As such, the interior cavity 22 extends through the firsttensile layer 32 and the second tensile layer 34, in between and aroundthe tethers 36, from the inner surface of the first polymeric sheet 16to the inner surface of the second polymeric sheet 18. The tensilelayers 32, 34 are not subjected to outward forces by the gas in theinterior cavity where the tensile layers are not bonded to the first andsecond polymeric sheets 16, 18. Accordingly, tethers 36B that extendbetween the portions of the tensile layer 32, 34 that are not bonded tothe polymeric sheets 16, 18 (e.g., the portions of the tensile layers32, 34 that are inward of the domed portions) may not be in tension.However, tethers 36A that extend between the portions of the tensilelayers 32, 34 bonded to the polymeric sheets 16, 18 (e.g., atinwardly-protruding bonds 50) are subjected to tension under asufficiently inflation pressure of the interior cavity 22.

Anti-weld material 48 is applied to selected areas of the outer surfaces45, 47, respectively, of the first and second tensile layers 32, 34 asbest shown in FIG. 15 . For example, anti-weld material may be ink jetprinted everywhere except at areas where protrusions of mold componentsused during thermoforming of the cushioning article 10 causeinwardly-protruding bonds 50 of the first polymeric sheet 16 and thesecond polymeric sheet 18, as further explained herein. Theinwardly-protruding bonds 50 of the first polymeric sheet 16 are alsoreferred to as a first plurality of bonds. Alternatively, anti-weldmaterial may be applied even where the bonds 50 are desired, if theanti-weld material is not activated. The anti-weld material 48, ifactivated, prevents the inner surfaces 42, 46 of the first and secondpolymeric sheets 16, 18 from bonding to the outer surfaces 45, 47 of thetensile component 30 during the manufacturing method 210 describedherein. The first tensile layer 32 is bonded to an inner surface 42 ofthe first polymeric sheet 16 at the inwardly-protruding bonds 50. Thesecond tensile layer 34 is bonded to an inner surface 46 of the secondpolymeric sheet 18 at inwardly-protruding bonds 50 as best shown in FIG.3 . The inwardly-protruding bonds 50 of the second polymeric sheet 18are also referred to as a second plurality of bonds. The first pluralityof bonds 50 are in a first region of the bladder 23 (e.g., on theproximal side in each of the forefoot, midfoot, and heel regions), andthe second plurality of bonds 50 are in a second region of the bladder23 (e.g., on the distal side in each of the forefoot, midfoot, and heelregions).

The tethers 36 restrain separation of the first and second polymericsheets 16, 18 to the maximum separated positions shown in FIG. 3 under agiven inflation pressure of gas in the interior cavity 22. The outwardforce of pressurized gas in the interior cavity 22 on the inner surfaces42, 46 of the first and second polymeric sheets 16, 18 places thetethers 36A at the inwardly-protruding bonds 50 in tension, and thetethers 36 prevent the tensile layers 32, 34 and polymeric sheets 16, 18from further outward movement away from one another. However, thetethers 36 do not present resistance to compression when under acompressive load. When pressure is exerted on the cushioning article 10such as due to a force of a dynamic impact of a wearer during running orother movements, the cushioning article 10 is compressed, and thepolymeric sheets 16, 18 move closer together with the tethers 36collapsing (i.e., going slack) in proportion to the pressure exerted onthe first and second polymeric sheets 16, 18 adjacent the particulartethers 36.

Prior to bonding to the first and second polymeric sheets 16, 18according to the method 210 disclosed herein, the tethers 36 of thetensile component 30 may all be initial lengths, and possibly allsubstantially the same length, and the first and second tensile layers32, 34 connected by the tethers 36 may have generally flat outersurfaces 45, 47, respectively, directly above the tethers 36 as shown inFIG. 15 . In FIG. 15 , the tethers 36 are represented in a slackenedstate as FIG. 15 represents the tensile component 30 prior to securementwithin a sealed, pressurized interior cavity 22.

Under the method 210 provided herein, although the tethers 36 areoriginally of the same length and the outer surfaces 45, 47 of the firstand second tensile layers 32, 34 and the outer surfaces 49, 54 of thefirst and second polymeric sheets 16, 18, respectively, are generallyflat directly above the tethers 36 (i.e., not contoured) prior tomanufacture of the cushioning article 10, the method of manufacturing210 produces inwardly-protruding bonds 50 that join the first polymericsheet 16 to the first tensile layer 32 that protrude from the firstpolymeric sheet 16 toward the second polymeric sheet 18 directly into aregion of the cavity 22 occupied by some of the tethers 36. In fact, inFIG. 3 , there are multiple inwardly-protruding bonds 50.

Each bond 50 in the first polymeric sheet 16 results from a respectiveprotrusion 51 of a mold component 53A (best shown in FIGS. 15 and 18 asa plurality of protrusions 51 arranged in closed shapes) that contactsthe first polymeric sheet 16 during the method of manufacturing 210disclosed herein. Each bond 50 in the second polymeric sheet 18 resultsfrom a respective protrusion 51 of a mold component 53B (also shown as aplurality of protrusions 51 arranged in closed shapes) that contacts thesecond polymeric sheet 18 during the method of manufacturing 210disclosed herein (see FIG. 15 ). FIG. 18 shows a representative moldcomponent 53A having the protrusions 51 in a first pattern that resultin the bond pattern 55A of inwardly-protruding bonds 50 of thecushioning article 10 shown in FIG. 1 . The mold component 53B isidentical to mold component 53A, and results in the same bond pattern55A on the second polymeric sheet 18. The mold component 53A is a firstmold insert, and may also be referred to as a shim. The mold component53B is a second mold insert. The bonds 50 are indicated with hiddenlines in FIGS. 1 and 2 as they protrude inward from the outer surfaces49, 54 shown.

The bonds 50 result in depressed grooves 52 at the outer surface 49 ofthe first polymeric sheet 16 and at the outer surface 54 of the secondpolymeric sheet 18. Only some of the bonds 50 and some of the grooves 52are indicated in FIGS. 1 and 2 for clarity. As best shown in FIGS. 1 and2 , the inwardly-protruding bonds 50 on the first polymeric sheet 16define closed shapes surrounding portions of the first polymeric sheet16. The inwardly-protruding bonds 50 on the second polymeric sheet 18define closed shapes surrounding portions of the second polymeric sheet18. In the embodiment shown, the closed shapes are polygons. Forexample, one closed shape is a pentagon, and is indicated in FIG. 1 bynumbering the bonds 50 that surround and define the closed shape asbonds 50A, 50B, 50C, 50D, and 50E. The corresponding grooves 52 arenumbered as 52A, 52B, 52C, 52D, and 52E.

Due to the pressure of the gas in the interior cavity 22, a portion 16Aof the first polymeric sheet 16 that is not bonded to the first tensilelayer 32 (i.e., unbonded) and is surrounded by the bonds 50A, 50B, 50C,50D, 50E defining the closed shape is displaced from the first tensilelayer 32 (i.e., lifted away from the first tensile layer) such that theportion 16A of the first polymeric sheet 16 has a domed surface 49Aextending away from the first tensile layer 32. The closed shape anddomed surface 49A indicated is only one of many closed shapes andresulting domes surfaces at the outer surface 49 of the first polymericsheet 16. Additional portions with domed surfaces 49B, 49C, 49D, 49E areindicated in FIG. 3 and may be referred to as domed portions. As isapparent from the plan view of FIG. 1 , the first polymeric sheet 16effectively has a multitude of rounded bubble-like shapes extending overeach of the forefoot region 17A, the midfoot region 17B, and the heelregion 17C of the cushioning article 10. As used herein, “domed” meansrounded, and need not be hemispherical.

Similarly, with reference to FIG. 2 , one closed shape at the secondpolymeric sheet 18 is a pentagon, indicated in FIG. 2 by numbering thebonds 50 that surround and define the closed shape as bonds 50F, 50G,50H, 50I, and 50J. The corresponding grooves 52 are numbered as 52F,52G, 52H, 52I, and 52J. Due to the pressure of the gas in the interiorcavity 22, a portion 18A of the second polymeric sheet 18 surrounded bythe bonds 50F, 50G, 50H, 50I, 50J defining the closed shape is displacedfrom the second tensile layer 34 such that the portion 18A of the secondpolymeric sheet 18 has a domed surface 54A extending away from thesecond tensile layer 34 as best shown in FIG. 3 . The closed shape andportion of second polymeric sheet 18 with a domed surface 54A indicatedis only one of many closed shapes and resulting portions with domessurfaces at the outer surface 54 of the second polymeric sheet 18.Additional portions with domed surfaces 54B, 54C, 54D, 54E are indicatedin FIG. 3 . As is apparent from the bottom view of FIG. 2 , the secondpolymeric sheet 18 effectively has a multitude of rounded, bubble-likeshapes extending over each of the forefoot region 17A, the midfootregion 17B, and the heel region 17C of the cushioning article 10.

Each inwardly-protruding bond 50 partially traverses the plurality oftethers 36 as shown in FIG. 3 . Stated differently, the bonds 50 aredirectly outward of different ones of the tethers 36 and protrude inwardon those tethers 36. The tethers 36 may be arranged in rows, with eachrow extending transversely between the tensile layers 32, 34, or in anyother pattern in which the tethers 36 extend between the tensile layers32, 34. Various different ones of the tethers 36 are aligned with thebonds 50. An inwardly-protruding bond 50 may traverse different rows ofthe tethers 36 such that different tethers from different rows arealigned with an inwardly-protruding bond 50, or an inwardly-protrudingbond 50 may be directly aligned with a single row. Some of theinwardly-protruding bonds 50 could be between rows of tethers.

With reference to FIG. 4 , the plurality of tethers 36 includes tethers36A aligned with the inwardly-protruding bonds 50 and tethers 36Bdisplaced from the inwardly-protruding bonds 50. Tethers 36A that arealigned with an inwardly-protruding bonds 50 are deformed by heat, bycompression of the overlaying materials of the first tensile layer 32and the second tensile layer 34, and/or by the overlaying material ofthe first tensile layer 32 and/or the second tensile layer 34 coatingthe tethers 36A such that the tethers 36A are shorter, thicker, or bothshorter and thicker at the inwardly-protruding bonds 50 than elsewhere.Such tethers are indicated with reference numeral 36A in FIG. 4 and maybe referred to as modified tethers 36A. However, references to tethers36 herein include tethers 36A and tethers 36B unless otherwisespecified.

When the interior cavity 22 is inflated, the modified tethers 36A resultin depressed grooves 52 in the outer surface 49 of the first polymericsheet 16, as indicated in FIG. 3 . When an inflation pressure of the gasin the interior cavity 22 against the inner surfaces of the polymericsheets 16, 18 is sufficient to cause the polymeric sheets 16, 18 totension the tethers 36A, the inwardly-protruding bonds 50 define thegrooves 52 at the outer surface 49 of the first polymeric sheet 16 andin the outer surface 54 of the second polymeric sheet 18. At each groove52, the cushioning article 10 is divided into what may be referred to asa first article portion 61 on one side of the groove 52 and a secondarticle portion 62 on the other side of the groove 52, as indicated inFIG. 4 with respect to the left-most groove 52 indicated. The firstarticle portion 61 is articulated relative to the second article portion62 along the groove 52. Stated differently, the outer surface 49 of thefirst polymeric sheet 16 at a first side of the inwardly-protruding bond50 (the first side indicated in FIG. 4 as portion 49D of outer surface49) is non-planar with the outer surface 49 of the first polymeric sheet16 at a second side of the inwardly-protruding bond 50 (the second sideindicated in FIG. 4 as portion 49C of outer surface 49), with the secondside opposite of the first side. The outer surface 54 of the secondpolymeric sheet 18 at a first side of the inwardly-protruding bond 50(the first side indicated in FIG. 4 as portion 54D of outer surface 54)is non-planar with the outer surface 54 of the second polymeric sheet 18at a second side of the inwardly-protruding bond 50 (the second sideindicated in FIG. 4 as portion 54C of outer surface 54), with the secondside opposite of the first side.

The grooves 52 may act as flexion axes of the cushioning article 10. Forexample, when the cushioning article 10 is included in the solestructure 12 of the article of footwear 14 in FIG. 9 , theinwardly-protruding bonds 50 and resulting grooves 52 may establishflexion axes of the sole structure 12. The bonds 50 may be configured sothat many of the bonds 50 fall lengthwise near or along a common axis toestablish flexion axes that may align with joints of the foot, such asthe metatarsal phalangeal joints, thereby increasing flexibility of thesole structure 12. Various flexion axes F1, F2 are indicated in FIG. 1 .Flexion axes increase flexibility of the cushioning article 10. In someembodiments, some of the bonds 50 may be aligned in a straight line fromthe medial side to the lateral side of the cushioning article, creatinga flexion axis that extends transversely across the entire cushioningarticle.

Referring to FIGS. 3 and 4 , each inwardly-protruding bond 50 at thefirst polymeric sheet 16 is spaced apart from the second polymeric sheet18, and each inwardly-protruding bond 50 at the second polymeric sheet18 is spaced apart from the first polymeric sheet 16 such that theinterior cavity 22 is narrowed but not closed at the inwardly-protrudingbonds 50. Gas in the interior cavity 22 can thus fluidly communicateacross any of the inwardly-protruding bonds 50 (i.e., between a bond 50on the first polymeric sheet 16 and a corresponding bond 50 on thesecond polymeric sheet 18). As shown in FIG. 4 , the first tensile layer32 is spaced apart from the second tensile layer 34 by a first distanceD1 at a location adjacent to the inwardly-protruding bond 50, and theinwardly-protruding bond 50 at the first polymeric sheet 16 and thefirst tensile layer 32 is spaced apart from the inwardly-protruding bond50 at the second polymeric sheet 18 and the second tensile layer 34 by asecond distance D2. The first distance D1 may be the distance betweenthe tensile layers 32, 34 at the tethers 36B that are not the modifiedtethers 36A. The second distance D2 may be the minimum distance betweenthe corresponding inwardly-protruding bonds 50 at the modified tethers36A (i.e., the distance at the most narrowed portion of the interiorcavity 22 between corresponding bonds 50 of the first and secondpolymeric sheets 16, 18). In an embodiment, the method of manufacturing210 may be controlled so that the second distance D2 is between 50percent and 80 percent of the first distance D1. Bonds 50 in this rangeof depth may create the most desirable amount of articulation. Forexample, factors that may influence the bond 50 and the extent of itsprotrusion toward the opposite first or second polymeric sheet 16, 18can be controlled to provide this desired ratio of the second distanceD2 to the first distance D1. Such factors may include the depth of theprotrusion 51 that creates the bond 50, the temperature of the moldinsert 53 or other mold components, the temperature of the components ofthe cushioning article 10, vacuum and/or inflation pressures in the moldcavity during manufacturing, the power of weld frequency if radiofrequency welding is used, and other factors.

Accordingly, a portion 22A of the interior cavity 22 at a first side ofcorresponding inwardly-protruding bonds 50 is in fluid communicationwith a portion 22B of the interior cavity 22 at a second side of thecorresponding inwardly-protruding bonds 50, with the second sideopposite of the first side, as indicated in FIG. 4 . The modifiedtethers 36A shown extending under the corresponding bonds 50 between thetwo portions 22A, 22B are narrow in diameter and allow gas to flowaround and between the tethers 36A from the portion 22A to the portion22B and vice versa. This allows the gas to be displaced from the portion22A to the portion 22B and from portion 22B to portion 22A whencompressive forces are applied to the cushioning article 10, such asduring impact of the article of footwear 14 with the ground Gin FIG. 9 .For example, as a foot rolls forward from heel to toe during a footstrike, the gas may be displaced from rearward in the cushioning article10 to a portion more forward in the cushioning article 10. Supportivecushioning provided by the interior cavity 22 can thus be provided inareas most needed during use of the cushioning article 10.

FIGS. 5-7 show stages of compression of the cushioning article 10 undercompressive force F applied normal to the domed surfaces of the firstand second polymeric sheets 16, 18, such as under dynamic compressiveloading during a foot strike when the cushioning article is a solecomponent of the sole structure 12 of FIG. 9 . During initial loading,the portions with domed surfaces 49B, 49C, 49D and 54B, 54C, 54D beginto flatten, and the gas in the interior cavity 22 becomes morepressurized as the volume of the cavity 22 decreases, as depicted by thechanges to the cushioning article 10 from FIG. 5 to FIG. 6 . Undercontinued loading, the domed surfaces may completely flatten, and thefirst and second polymeric sheets 16, 18 contact the first and secondtensile components 32, 34 between the bonds 50. With even furtherloading the shortened tethers 36A will collapse. When the dynamiccompressive forces F are removed, the tethers 36A will return to atensioned state, and the portions of the first and second polymericsheets 16, 18 between the closed shapes of the bonds 50 will return totheir domed shapes.

FIGS. 10-11 show another embodiment of a cushioning article 110. Thecushioning article 110 has many of the same features as cushioningarticle 10, and these are shown with like reference numbers and are asdescribed with respect to the cushioning article 10. The sheets 16, 18form a bladder 123, with the first polymeric sheet establishing theproximal side of the bladder 123 and the second polymeric sheet 18establishing the distal side of the bladder 123. In the cushioningarticle 110, anti-weld material is applied only forward of arepresentative dividing line 113 on the first and second polymericsheets 16, 18 and/or on the tensile layers 32, 34 where bonding is notdesired. Accordingly, as indicated in FIGS. 12 and 14 , the first andsecond polymeric sheets 16, 18 have portions with inner surfaces 42, 46that are surrounded by a first plurality of bonds 50 arranged in closedshapes, and are displaced from the outer surfaces 45, 47 of the adjacentfirst and second tensile layers 32, 34, respectively, forming the domedsurfaces 49F, 49G, 54F, 54G, etc., only in a first region of the firstpolymeric sheet 16, which is the region forward of the dividing line113.

In a second region of the first polymeric sheet 16, which is a regionrearward of the dividing line 113 in FIGS. 10, 11, 12, and 14 , theinner surface 42 of the first polymeric sheet 16 is bonded to an outersurface 45 of the first tensile layer 32 at surface bonds 40, and theinner surface 46 of the second polymeric sheet 18 is bonded to the outersurface 47 of the second tensile layer 34 at surface bonds 44. A mold isused so that protrusions 51 contact the only first polymeric sheet 16 inthe second region. A second plurality of inwardly-protruding bonds 50arranged in closed shapes are formed at the first polymeric sheet 16 inthe second region, but not in the second polymeric sheet 18 in thesecond region. When the interior cavity 22 is inflated, the modifiedtethers 36A result in depressed grooves 52 in the outer surface 49 ofthe first polymeric sheet 16 and in the outer surface 54 of the secondpolymeric sheet 18 at the inwardly-protruding bonds 50. When aninflation pressure of the gas in the interior cavity 22 is sufficient totension the plurality of tethers 36A at the inwardly-protruding bonds50, the inwardly-protruding bonds 50 define grooves 52 at the outersurface 49 of the first polymeric sheet 16 and at the outer surface 54of the second polymeric sheet 18. Although the first and the secondpluralities of bonds 50 are shown on the first polymeric sheet 16 on theproximal side, the cushioning article 110 could be used in an article offootwear with the first polymeric sheet on the distal side.

The tension of the modified tethers 36A also causes recesses 56 in theouter surface 54 of the second polymeric sheet 18 opposite each of theinwardly-protruding bonds 50 of the first polymeric sheet 16. The secondpolymeric sheet 18 is recessed inward toward a corresponding groove 52and inwardly-protruding bond 50 at each recess 56 when the interiorcavity 22 is inflated. The grooves 52 are generally deeper than therecesses 56, which may cause the cushioning article 10 to be articulatedin the second region even when not under a compressive load, as thecushioning article 10 curves slightly upward at each groove 52. Stateddifferently, the physical deformation of the first polymeric sheet 16and the first tensile layer 32 combined with the tension of the modifiedtethers 36A will cause the grooves 52 to be deeper than the recesses 56,which result only from the tension of the shortened modified tethers36A. Accordingly, the second region of the cushioning article 10 mayhave an articulated shape, such as when not under loading at the grooves52, as shown in FIG. 14 , where the second region is slightly curvedupward from the horizontal line H. Additionally, the grooves 52 andrecesses 56 together encourage articulation of the cushioning article 10to occur at the grooves 52, as the overall thickness of the cushioningarticle 10 is reduced at the grooves 52, decreasing bending stiffness ofthe cushioning article at the grooves 52. In contrast, the cushioningarticle 10 that has grooves 52 on both sides due to inwardly-protrudingbonds 50 at both the first and second polymeric sheets 16, 18 remainsmore level and less articulated than the cushioning article 110 when notunder loading, but, like cushioning article 110, encourages articulationat the grooves 52.

Due to the surface bonds 40, any rounding or doming of the polymericsheet 16 at the closed shapes surrounded by inwardly-protruding bonds 50is lessened, and does not include any displacement of the firstpolymeric sheet 16 from the first tensile layer 32. In FIG. 14 , thefirst and second tensile layers 32, 34 are indicated with hidden linesfollowing the contours of the first and second polymeric sheets 16, 18in the second region, and are intended to indicate that the innersurfaces 42, 46 are bonded to the outer surfaces 45, 47 in the entiretyof the second region. As shown in FIG. 12 , at a firstinwardly-protruding bond 50K, the interior cavity 22 is narrowed but notclosed, so gas can communicate across the bond 50K and the correspondingbond 50 of the second polymeric sheet 18. At a secondinwardly-protruding bond 50L in the second region, the interior cavity22 is narrowed but not closed, so gas can communicate across the bond50L and a corresponding bond 50 of the second polymeric sheet 18.

FIG. 15 shows the components of the cushioning article 10 in an explodedview and positioned between components of a mold 66. More specifically,the components of mold 66 (also referred to herein as mold components)include a first mold portion 66A, a second mold portion 66B, a firstmold insert 53A, and a second mold insert 53B. The components of themold necessary to manufacture the cushioning article 110 are the sameexcept that the second mold insert 53B would not have protrusions 51 asno inwardly-protruding bonds are created at the second polymeric sheet18 in the cushioning article 110. Alternatively, the second mold portion66B could be modified so that no mold insert is necessary, and the moldsurface contacting the outer surface 54 of the second polymeric sheet 18has no protrusions 51. FIG. 16 shows the components of the cushioningarticle 10 in a mold cavity 68 of the mold 66 defined by the moldcomponents with the mold 66 in a closed position. Although the polymericsheets 16, 18 are in contact with the tensile components 32, 34 in themold 66, anti-weld material prevents bonding of the polymeric sheets 16,18 to the tensile components 32, 34 where the anti-weld material isdisposed.

FIGS. 21-24 show another embodiment of a cushioning article 310. Thecushioning article 310 has many of the same features as cushioningarticles 10 and 110, and these are shown with like reference numbers andare as described with respect to the cushioning article 310. In thecushioning article 310, anti-weld material is applied to the innersurfaces of only the second polymeric sheet 18 and/or on the tensilelayer 34. Accordingly, as indicated in FIG. 23 , the first polymericsheet 16 is at a proximal side of the cushioning article 310 and has aplurality of bonds 50 (referred to as a second plurality of bonds) in asecond region of the bladder 323 which is the entire forefoot region17A, midfoot region 17B, and heel region 17C on a distal side of thebladder 323 (defining closed shapes, and portions surrounded by theclosed shapes having surface bonds 40 to the first tensile layer 32. Thesecond polymeric sheet 18 has portions with a first plurality of bonds50 arranged in closed shapes surrounding portions with inner surfaces 46that are displaced from the outer surface 47 of the adjacent secondtensile layer 34, forming the domed surfaces 54F, 54G, 54H, 54I, 54J,etc., in a first region of the second polymeric sheet 18, which is theentire forefoot region 17A, midfoot region 17B, and heel region 17C on adistal side of the bladder 23.

In a second region of the first polymeric sheet 16, which is a regionrearward of the dividing line 113 in FIGS. 10, 11, 12, and 14 , theinner surface 42 of the first polymeric sheet 16 is bonded to an outersurface 45 of the first tensile layer 32 at surface bonds 40, and theinner surface 46 of the second polymeric sheet 18 is bonded to the outersurface 47 of the second tensile layer 34 at surface bonds 44. A mold isused so that protrusions 51 contact the only first polymeric sheet 16 inthe second region. Inwardly-protruding bonds 50 are formed at the firstpolymeric sheet 16 in the second region, but not in the second polymericsheet 18 in the second region. When the interior cavity 22 is inflated,the modified tethers 36A result in depressed grooves 52 in the outersurface 49 of the first polymeric sheet 16 and in the outer surface 54of the second polymeric sheet 18 at the inwardly-protruding bonds 50.When an inflation pressure of the gas in the interior cavity 22 issufficient to tension the plurality of tethers 36A at theinwardly-protruding bonds 50, the inwardly-protruding bonds 50 definegrooves 52 at the outer surface 49 of the first polymeric sheet 16 andat the outer surface 54 of the second polymeric sheet 18.

A method 210 of manufacturing a cushioning article, such as cushioningarticle 10, 110, or 310 is shown in the flow chart of FIG. 20 , and isdescribed with reference to FIGS. 15 and 16 . The method 210 may beginwith block 211, disposing anti-weld material on the inner surface of thefirst polymeric sheet 16, or on the outer surface of the first tensilelayer 32. In manufacturing the cushioning article 110, the anti-weldmaterial would only be disposed forward of the dividing line 113, suchas in the first region of the first polymeric sheet 16. In manufacturingthe cushioning article 10, the method also includes block 212, disposinganti-weld material on the inner surface of the second polymeric sheet 18or on the outer surface of the second tensile layer 34. In manufacturingcushioning article 110, block 212 may be omitted for some regions of thepolymeric sheet 18 as discussed herein. In manufacturing cushioningarticle 310, block 211 may be omitted. The anti-weld material disposedin blocks 211 and 212 is not disposed in locations where bonds 50 aredesired. For example, the anti-weld material may be disposed forward ofdividing line 113 as described, but avoiding the areas of the sheets 16,18 and the tensile layers 32, 34 where bonds are desired. The correctplacement of anti-weld material to achieve this may be by ink-jetprinting the correct pattern on the surfaces of the sheets 16, 18 and/ortensile layers. Alternatively, the anti-weld material may be disposed atlocations where bonds are desired, if it is not activated at thoselocations.

In block 213, a first mold insert 53A with a first protrusion pattern55A (i.e., the pattern of protrusions 51 arranged in closed shapes) issecured to the first mold portion 66A, as best shown in FIG. 18 . Forexample, as indicated in FIG. 15 , the first mold insert 53A hasopenings 70 that receive fasteners 72. The fasteners 72 extend intoopenings 74 in the first mold portion 66A to secure the first moldinsert 53A to the first mold portion 66A. The openings 74 are in arecess 75 of the first mold portion 66A, and the mold insert 53A fitswithin the recess 75 so that the surface 76 is flush with adjacentsurfaces 78 of the first mold portion 66A. The openings 70, 74 and thefasteners 72 may be threaded, for example. When disposed as set forth inblock 212, the mold insert 53A is therefore in and partially defines themold cavity 68.

When manufacturing the cushioning article 10 or 310, a second moldinsert 53B having a plurality of protrusions 51 arranged in closedshapes will be secured to the second mold portion 66B in block 214 inthe same manner as first mold insert 53A is secured to first moldportion 66A. For some configurations, the first and second mold portions66A, 66B may be configured with the plurality of protrusions 51 arrangedin closed shapes such that no mold inserts 53A, 53B need be used.However, the use of mold inserts 53A, 53B allows the same mold portions66A, 66B to be used in manufacturing cushioning articles with differentbond patterns simply by changing either or both mold inserts 53A, 53Bfor those with an alternative pattern of protrusions. When manufacturingthe cushioning article 110, no protrusions are necessary adjacent thesecond polymeric sheet 18 rearward of line 113 as no inwardly-protrudingbonds 50 are created in the second polymeric sheet 18 in this region.Accordingly, in manufacturing the cushioning article 110, the secondmold portion 66B configured to align rearward of line 113 may beprovided without protrusions and with a surface configured to shape theouter surface of the second polymeric sheet 18.

Next, in block 215, prior to disposing the components of the cushioningarticle 10 into the open mold cavity 68, the components of thecushioning article 10 (or cushioning article 110 or 310), the moldcomponents 53A, 53B, 66A, 66B, or both, may be pre-heated to helpexpedite the subsequent thermoforming that occurs via the combinedblocks 218, 220.

In block 216, the first and second polymeric sheets 16, 18 and thetensile component 30 are then disposed in the mold cavity 68, with thefirst tensile layer 32 positioned adjacent the first polymeric sheet 16,the second tensile layer 34 positioned adjacent the second polymericsheet 18, and the plurality of tethers 36 connecting the first tensilelayer to the second tensile layer. Block 216 may comprise placing firstand second polymeric sheets 16, 18 and the tensile component 30 betweenthe open mold portions 66A, 66B. This may be accomplished by the use ofshuttle frames (not shown) that separately hold the various componentsof the cushioning article 10, 110, or 310 in alignment with one anotherand with the mold components 66A, 66B, 53A, 53B, as shown in FIG. 15 .When manufacturing the cushioning article 110, the first and secondpolymeric sheets 16, 18 may already by bonded to the respective tensilelayers 32, 34 of the tensile component 30 rearward of the dividing line113 when placed in the mold cavity 68, such as by lamination or by theuse of adhesive. Alternatively, as shown in FIG. 15 , the first andsecond polymeric sheets 16, 18 may not yet be bonded to the tensilecomponent 30. Once the components of the cushioning article 10, 110, or310 are positioned in the mold cavity 68, one or both of the moldcomponents 66A, 66B is translated toward the other mold component toclose the mold cavity 68.

Next, in block 218, the first polymeric sheet 16 and the secondpolymeric sheet 18 are conformed to components of the mold 66, as shownin FIG. 16 . For example, the outer surface 49 of the first polymericsheet 16 is conformed to the surface 76 of the mold insert 53A. Thesurface 76 includes the plurality of protrusions 51. Portions of theouter surface 49 of the first polymeric sheet 16 are conformed directlyto the mold surface 78 of the first mold portion 66A adjacent to thefirst mold insert 53A. Conforming of the first polymeric sheet 16 to thesurface 76, including the plurality of protrusions 51, depresses thefirst polymeric sheet 16 toward the second polymeric sheet 18 at theplurality of protrusions 51, with the plurality of protrusions 51directly outward of some of the plurality of tethers 36. In block 218,the outer surface 54 of the second polymeric sheet 18 is also conformedto the surface 77 of the second mold insert 53B and to the mold surface79 of the second mold portion 66B adjacent to the second mold insert53B, indicated in FIG. 16 . Conforming the polymeric sheets 16, 18 tothe surfaces of the mold inserts 53A, 53B and the mold portions 66A, 66Bmay include applying a vacuum to the mold cavity 68 to pull thepolymeric sheets 16, 18 against the surfaces 76, 77, 78, 79.Alternatively or in addition, conforming the polymeric sheets 16, 18 tothe surfaces may include pressurizing the mold cavity 68, therebycompressing the polymeric sheets 16, 18 against the surfaces 76, 77, 78,79.

After or contemporaneously with the first and second polymeric sheets16, 18 conforming to the surfaces 76, 77, 78, 79 in block 218, the firsttensile layer 32 may be thermally bonded to the first polymeric sheet 16and the second tensile layer 34 may be thermally bonded to the secondpolymeric sheet 18 opposite the first tensile layer 32 in block 220. Theheating of the polymeric sheets 16, 18, the tensile layers 32, 34,and/or the mold components 53A, 53B, 66A, 66B in addition to the vacuumand/or pressurization of the mold cavity 68 enables the thermal bondingat the surface bonds 40, 44 and the inwardly-protruding bonds 50. Whenthe components of the cushioning article 10 are cooled, the bonds 40,44, 50 remain. Conforming in block 218 and thermally bonding in block220 may be referred to as thermoforming, and produces theinwardly-protruding bonds 50 at the protrusions 51 that join the firstpolymeric sheet 16 and the first tensile layer 32 and partially traversethe plurality of tethers 36, with the inwardly-protruding bonds 50protruding toward the second polymeric sheet 18 but remaining spacedapart from the second tensile layer 34 and the second polymeric sheet 18as described with respect to FIG. 3 .

The thermal bonding of block 220 may include heating the first polymericsheet 16 and the second polymeric sheet 18 prior to disposing the firstpolymeric sheet 16 and the second polymeric sheet 18 in the mold cavity68. Alternatively or in addition, the thermal bonding may includeheating one or more of the mold components 53A, 53B, 66A, 66B, or radiofrequency welding via the mold 66.

Following block 220 or contemporaneously with block 220, the method 210may include block 222, bonding the first polymeric sheet 16 to thesecond polymeric sheet 18 at the peripheral bond 20 such that the firstpolymeric sheet 16 and the second polymeric sheet 18 at least partiallyenclose the interior cavity 22 containing the tensile component 30. Forexample, bonding the first polymeric sheet 16 and the second polymericsheet 18 at the peripheral bond 20 in block 222 may include compressingthe first polymeric sheet 16 and the second polymeric sheet 18 betweenthe first mold portion 66A and the second mold portion 66B in the closedposition, as shown in FIG. 16 . A small portion of the periphery of thefirst and second polymeric sheets 16, 18 can be left unbonded, such asat an inflation port 82 molded into the sheets in blocks 218 and 220.

After block 222, the mold cavity 68 may be opened in block 224 bytranslating one or both of the mold portions 66A, 66B away from oneanother. The cushioning article 10 can then be removed from the moldcavity 68 in block 226.

In block 228, the interior cavity 22 can be inflated to a desiredinflation pressure, such as through the inflation port 82 of FIG. 1 .For example, a fill tube may fit into the inflation port 82 or may beintegrally formed by the sheets 16, 18 at the inflation port 82. Priorto or after inflating the interior cavity 22 in block 228, excessmaterial of the sheets 16, 18 around the peripheral bond 20 can betrimmed. Gas, such as air, can be dispensed from a pressurized source orpumped into the interior cavity 22 through the inflation port 82 from apressurized source. In some embodiments, the interior cavity 22 is notinflated, but instead simply retains gas at atmospheric pressure.

The interior cavity 22 is sealed in block 230. In the embodiment shown,this may be accomplished by sealing the inflation port 82, such as bythermally bonding the sheets 16, 18 to one another at the inflation port82, adhering the sheets 16, 18 to one another at the inflation port 82,or plugging the inflation port 82. In FIG. 1 , the sheets 16, 18 and anyfill tube is already trimmed, and the inflation port 82 is sealed. Thecushioning article 10, 110, or 310 is completely manufactured once block230 is completed, and is ready to be assembled in the article offootwear 14. If the interior cavity 22 is inflated to a sufficientpressure, portions of the polymeric sheet 16 and/or 18 of the cushioningarticle 10, 110, or 310 that forms domed portions with domed surfaces49A-49D, 54A-54J, etc., and the plurality of tethers 36A at the bonds 50are tensioned, creating the grooves 52 in the outer surface 49 of thefirst polymeric sheet 16 and at the outer surface 54 of the secondpolymeric sheet 18 at the inwardly-protruding bonds 50, therebyarticulating the cushioning article 10, 110, or 310 as discussed withrespect to FIG. 6 , with the grooves 52 establishing flexion axes.

It should be appreciated that, although in FIGS. 15-16 the moldcomponent having the protrusions 51 that create the inwardly-protrudingbonds 50 is a mold insert 53A and/or 53B, either or both of the moldportions 66A, 66B could have one or more protrusions, and no mold insertneed be used. However, the use of mold inserts may allow the productionof cushioning articles having different bond patterns with lower toolingexpense. For example, the same mold portions 66A, 66B may be used with adifferent tooling insert having a different pattern of protrusions toproduce cushioning articles with different bond patterns. For example,FIG. 19 shows a different mold insert 53AA with a different pattern 55AAof protrusions 51. The protrusions 51 of the mold insert 53AA areshaped, dimensioned, or positioned differently than the protrusions 51of the first mold insert 53A such that the pattern of protrusions 51 ofmold insert 53AA is different than the first pattern of protrusions ofmold insert 53A.

After manufacturing the cushioning article having a first bond pattern(i.e., a first pattern of inwardly-protruding bonds corresponding to thefirst pattern of protrusions of the first mold insert 53A), the method210 may include block 232, removing the first mold insert 53A from themold cavity 68. Then, in block 234, the different mold insert 53AA maybe secured to the mold portion 66A, using fasteners 72 extending throughopenings 70, 74 as described with respect to the mold insert 53A. Moldinsert 53B may also be replaced with a different mold insert with adifferent pattern of protrusions. With the mold insert 53AA now disposedin the mold cavity 68, and potentially a different mold insert securedto mold portion 66B and disposed in the cavity 68, blocks 211 to 230 ofthe method 210 can now be repeated to manufacture a second cushioningarticle that is a full length sole component having a different bondpattern than the first full length sole component produced using moldinserts 53A, 53B the different bond pattern being a pattern ofinwardly-protruding bonds 50 as described herein, but corresponding tothe different pattern of protrusions of the different mold insert 53AA,for example.

For example, in repeating blocks 211 to 230, block 216 is repeated bydisposing a subsequent first polymeric sheet 16, a subsequent secondpolymeric sheet 18, and a subsequent tensile component 30 in the moldcavity 68 with the subsequent tensile component between the subsequentfirst polymeric sheet and the subsequent second polymeric sheet. Block218 is repeated by conforming the subsequent first polymeric sheet tothe different mold insert 53AA and the subsequent second polymeric sheetto a different mold insert or to another one of the mold components(e.g., a mold component similar to mold component 66B), respectively,the conforming depressing the subsequent first polymeric sheet towardthe subsequent second polymeric sheet at the second protrusion 51 (i.e.,at one of the protrusions 51 of the different mold insert 53AA), withthe second protrusion directly outward of the subsequent tensilecomponent. For example, block 220 is repeated, thermally bonding thefirst tensile layer of the subsequent tensile component to thesubsequent first polymeric sheet and the second tensile layer of thesubsequent tensile component to the subsequent second polymeric sheet toproduce a second inwardly-protruding bond 50 at the second protrusionpartially traversing the subsequent tensile component. The same moldportions and mold cavity thus provide a second cushioning article with adifferent bond pattern than the first cushioning article due to thedifferent mold insert 53AA, and simply by removing the first mold insert53A and replacing it with the different mold insert 53AA, and, whenmanufacturing a cushioning article with inwardly-protruding bonds 50 atthe second polymeric sheet 18, such as cushioning article 10,potentially replacing the second mold insert 53B with a different moldinsert.

To assist and clarify the description of various embodiments, variousterms are defined herein. Unless otherwise indicated, the followingdefinitions apply throughout this specification (including the claims).Additionally, all references referred to are incorporated herein intheir entirety.

An “article of footwear”, a “footwear article of manufacture”, and“footwear” may be considered to be both a machine and a manufacture.Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots,etc.), as well as discrete components of footwear articles (such as amidsole, an outsole, an upper component, etc.) prior to final assemblyinto ready to wear footwear articles, are considered and alternativelyreferred to herein in either the singular or plural as “article(s) offootwear” or “footwear”.

“A”, “an”, “the”, “at least one”, and “one or more” are usedinterchangeably to indicate that at least one of the items is present. Aplurality of such items may be present unless the context clearlyindicates otherwise. All numerical values of parameters (e.g., ofquantities or conditions) in this specification, unless otherwiseindicated expressly or clearly in view of the context, including theappended claims, are to be understood as being modified in all instancesby the term “about” whether or not “about” actually appears before thenumerical value. “About” indicates that the stated numerical valueallows some slight imprecision (with some approach to exactness in thevalue; approximately or reasonably close to the value; nearly). If theimprecision provided by “about” is not otherwise understood in the artwith this ordinary meaning, then “about” as used herein indicates atleast variations that may arise from ordinary methods of measuring andusing such parameters. As used in the description and the accompanyingclaims, unless stated otherwise, a value is considered to be“approximately” equal to a stated value if it is neither more than 5percent greater than nor more than 5 percent less than the stated value.In addition, a disclosure of a range is to be understood as specificallydisclosing all values and further divided ranges within the range.

The terms “comprising”, “including”, and “having” are inclusive andtherefore specify the presence of stated features, steps, operations,elements, or components, but do not preclude the presence or addition ofone or more other features, steps, operations, elements, or components.Orders of steps, processes, and operations may be altered when possible,and additional or alternative steps may be employed. As used in thisspecification, the term “or” includes any one and all combinations ofthe associated listed items. The term “any of” is understood to includeany possible combination of referenced items, including “any one of” thereferenced items. The term “any of” is understood to include anypossible combination of referenced claims of the appended claims,including “any one of” the referenced claims.

For consistency and convenience, directional adjectives may be employedthroughout this detailed description corresponding to the illustratedembodiments. Those having ordinary skill in the art will recognize thatterms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”,etc., may be used descriptively relative to the figures, withoutrepresenting limitations on the scope of the invention, as defined bythe claims.

The term “longitudinal” refers to a direction extending a length of acomponent. For example, a longitudinal direction of an article offootwear extends between a forefoot region and a heel region of thearticle of footwear. The term “forward” or “anterior” is used to referto the general direction from a heel region toward a forefoot region,and the term “rearward” or “posterior” is used to refer to the oppositedirection, i.e., the direction from the forefoot region toward the heelregion. In some cases, a component may be identified with a longitudinalaxis as well as a forward and rearward longitudinal direction along thataxis. The longitudinal direction or axis may also be referred to as ananterior-posterior direction or axis.

The term “transverse” refers to a direction extending a width of acomponent. For example, a transverse direction of an article of footwearextends between a lateral side and a medial side of the article offootwear. The transverse direction or axis may also be referred to as alateral direction or axis or a mediolateral direction or axis.

The term “vertical” refers to a direction generally perpendicular toboth the lateral and longitudinal directions. For example, in caseswhere a sole structure is planted flat on a ground surface, the verticaldirection may extend from the ground surface upward. It will beunderstood that each of these directional adjectives may be applied toindividual components of a sole structure. The term “upward” or“upwards” refers to the vertical direction pointing towards a top of thecomponent, which may include an instep, a fastening region and/or athroat of an upper. The term “downward” or “downwards” refers to thevertical direction pointing opposite the upwards direction, toward thebottom of a component and may generally point towards the bottom of asole structure of an article of footwear.

The “interior” of an article of footwear, such as a shoe, refers toportions at the space that is occupied by a wearer's foot when thearticle of footwear is worn. The “inner side” of a component refers tothe side or surface of the component that is (or will be) orientedtoward the interior of the component or article of footwear in anassembled article of footwear. The “outer side” or “exterior” of acomponent refers to the side or surface of the component that is (orwill be) oriented away from the interior of the article of footwear inan assembled article of footwear. In some cases, other components may bebetween the inner side of a component and the interior in the assembledarticle of footwear. Similarly, other components may be between an outerside of a component and the space external to the assembled article offootwear. Further, the terms “inward” and “inwardly” refer to thedirection toward the interior of the component or article of footwear,such as a shoe, and the terms “outward” and “outwardly” refer to thedirection toward the exterior of the component or article of footwear,such as the shoe. In addition, the term “proximal” refers to a directionthat is nearer a center of a footwear component, or is closer toward afoot when the foot is inserted in the article of footwear as it is wornby a user. Likewise, the term “distal” refers to a relative positionthat is further away from a center of the footwear component or isfurther from a foot when the foot is inserted in the article of footwearas it is worn by a user. Thus, the terms proximal and distal may beunderstood to provide generally opposing terms to describe relativespatial positions.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Any feature of any embodiment may be used in combinationwith or substituted for any other feature or element in any otherembodiment unless specifically restricted. Accordingly, the embodimentsare not to be restricted except in light of the attached claims andtheir equivalents. Also, various modifications and changes may be madewithin the scope of the attached claims.

While several modes for carrying out the many aspects of the presentteachings have been described in detail, those familiar with the art towhich these teachings relate will recognize various alternative aspectsfor practicing the present teachings that are within the scope of theappended claims. It is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative and exemplary of the entire range of alternativeembodiments that an ordinarily skilled artisan would recognize asimplied by, structurally and/or functionally equivalent to, or otherwiserendered obvious based upon the included content, and not as limitedsolely to those explicitly depicted and/or described embodiments.

What is claimed is:
 1. A method of manufacturing a cushioning article,the method comprising: disposing anti-weld material on at least one ofan inner surface of a first polymeric sheet and an outer surface of afirst tensile layer of a tensile component; wherein the tensilecomponent includes the first tensile layer, a second tensile layer, anda plurality of tethers connecting the first tensile layer to the secondtensile layer; conforming the first polymeric sheet and a secondpolymeric sheet to components of a mold, said conforming depressing thefirst polymeric sheet toward the second polymeric sheet at protrusionsof the mold arranged in closed shapes and with the protrusions atlocations that include the plurality of tethers located between thefirst polymeric sheet and the second polymeric sheet; and thermallybonding the first tensile layer to the first polymeric sheet and thesecond tensile layer to the second polymeric sheet opposite the firsttensile layer; wherein said thermally bonding produces a plurality ofbonds at the protrusions that join the first polymeric sheet to thefirst tensile layer and partially traverse the plurality of tethers, theplurality of bonds protruding toward the second polymeric sheet andspaced apart from the second tensile layer and the second polymericsheet; wherein portions of the first polymeric sheet surrounded by theplurality of bonds are separated from the first tensile layer due to theanti-weld material and are displaceable from the first tensile layer. 2.The method of claim 1, further comprising: bonding the first polymericsheet to the second polymeric sheet at a peripheral bond such that thefirst polymeric sheet and the second polymeric sheet at least partiallyenclose an interior cavity containing the tensile component, theplurality of tethers spanning across the interior cavity from the firsttensile layer to the second tensile layer, the plurality of bondsprotruding inward such that the interior cavity is narrowed at theplurality of bonds.
 3. The method of claim 2, further comprising:inflating and sealing the interior cavity; wherein said inflating liftsthe portions of the first polymeric sheet surrounded by the plurality ofbonds away from the first tensile layer to form a plurality of domedportions, and tensions the plurality of tethers at the plurality ofbonds to create a plurality of grooves in an outer surface of the firstpolymeric sheet at the plurality of bonds, thereby articulating thecushioning article.
 4. The method of claim 3, wherein the plurality ofbonds are linear bonds arranged in closed polygonal shapes eachsurrounding a different one of the domed portions.
 5. The method ofclaim 4, wherein the cushioning article is a footwear sole structure,and the closed polygonal shapes of the linear bonds surrounding threeconsecutive ones of the domed portions are arranged so that eachincludes a linear bond aligned with a flexion axis of the footwear solestructure.
 6. The method of claim 5, wherein the closed polygonal shapesof the linear bonds surrounding the three consecutive ones of the domedportions are pentagons.
 7. The method of claim 3, wherein: the firsttensile layer is spaced apart from the second tensile layer by a firstdistance at the domed portions; the plurality of bonds are spaced apartfrom the second tensile layer by a second distance; and the seconddistance is between 50 percent and 80 percent of the first distance. 8.The method of claim 3, wherein: the plurality of tethers includestethers aligned with the plurality of bonds and tethers displaced fromthe plurality of bonds; and the tethers aligned with the plurality ofbonds are shorter, thicker, or both shorter and thicker than the tethersdisplaced from the plurality of bonds.
 9. The method of claim 2, whereinthe components of the mold include a first mold portion and a secondmold portion, at least one of the first mold portion and the second moldportion is translatable relative to the other of the first mold portionand the second mold portion between an open position and a closedposition; and said bonding the first polymeric sheet and the secondpolymeric sheet at the peripheral bond includes compressing the firstpolymeric sheet and the second polymeric sheet between the first moldportion and the second mold portion in the closed position.
 10. Themethod of claim 1, wherein the mold includes a mold portion and a moldinsert, and the method further comprising: prior to said conforming,securing the mold insert to the mold portion, and wherein the moldinsert has the protrusions.
 11. The method of claim 10, wherein the moldinsert is a first mold insert, the protrusions are a first plurality ofprotrusions, the mold portion is a first mold portion, the plurality ofbonds is a first plurality of bonds, and further comprising: securing asecond mold insert to a second mold portion of the mold; wherein thesecond mold insert has a second plurality of protrusions directlyopposite the first plurality of protrusions; and wherein said conformingand said thermally bonding produces a second plurality of bonds at thesecond plurality of protrusions partially traversing the tensilecomponent opposite the first plurality of bonds, the second plurality ofbonds protruding toward the first plurality of bonds and the firstpolymeric sheet, and spaced apart from the first plurality of bonds, thefirst tensile layer, and the first polymeric sheet.
 12. The method ofclaim 10, wherein the cushioning article is a first cushioning article,the protrusions are a first plurality of protrusions, the firstplurality of bonds has a first bond pattern, and the method furthercomprising manufacturing a second cushioning article by: removing themold insert from the mold portion; securing a second mold insert havinga second plurality of protrusions to the mold portion, wherein thesecond plurality of protrusions is shaped, dimensioned, or positioneddifferently than the first plurality of protrusions; and conforming asubsequent first polymeric sheet and a subsequent second polymeric sheetto the second mold insert and to another one of the components of themold, respectively, with a subsequent tensile component between thesubsequent first polymeric sheet and the subsequent second polymericsheet; wherein said conforming depresses the subsequent first polymericsheet toward the subsequent second polymeric sheet at the secondplurality of protrusions, with the protrusions of the second pluralityof protrusions at locations that include the subsequent tensilecomponent between the subsequent first polymeric sheet and thesubsequent second polymeric sheet, thereby producing a second pluralityof bonds at the second plurality of protrusions partially traversing thesubsequent tensile component, the mold thus providing the secondcushioning article with a different bond pattern than the first bondpattern of the first cushioning article due to the second mold insert.13. The method of claim 1, wherein said conforming the first polymericsheet and the second polymeric sheet to components of the mold is byvacuum, compression, or both; and wherein said thermal bonding includesat least one of: heating the first polymeric sheet and the secondpolymeric sheet; heating the components of the mold; or radio frequencywelding.